涂裝異常分析及改善對策

1、涂裝異常分析及改善對策漆膜缺陷原因分類:涂料問題(Product problems應(yīng)用不良(Application problems設(shè)備因素(Equipment problems環(huán)境因素(Environment Cause顏色問題(Colour problems漆膜硬度不夠(weak:描述(DESCRIPTION-表現(xiàn)為漆膜軟, 很容易被劃傷;相應(yīng)的耐溶劑性能表現(xiàn)差。原因(cause:通常是漆膜樹酯交鏈不夠好,而交鏈不夠的主要因素有:1樹酯分子選擇不合適;2未完全干燥;3高溫漆或雙組份漆烘烤溫度不夠;4雙組份漆固化劑配比不對。起泡(blowing:起泡的原因(cause:通常是基底有銹跡(擴大

2、、污垢、小凹孔、磷化渣質(zhì)、水汽等被封在漆膜底下,漆膜在烤干或受熱(受熱膨脹時,這些物質(zhì)彭漲將漆膜頂起造成。溶劑泡(Solvent Popping 描述(DESCRIPTION新噴漆膜表面有直徑小于1MM的小氣泡。Open topped blisters up to 1mm in diameter on the surface of the most recently applied paint film.起因(CAUSEAir or solvent vapour trapped by fast drying paint forming a skin. This may be due to:a

3、天那水太差或太快干。poor quality or too fast thinner.b 噴得太厚或兩層漆之間干燥時間不夠。excessive film thickness, or insufficient drying time between coats.c 壓縮空氣壓力太低。compressed air pressure too low.d 加熱太快。drying temperature too high, heat source too close to the film, too hot, or applied too soon.預(yù)防(PREVENTIONa 確保工件表面清潔Ensu

4、re that the surface is scrupulously clean.b 使用合適的天那水。Use only recommended thinner.c 每層漆膜厚度合適,并適當(dāng)閃干Apply paint in thin, wet films. Allow sufficient drying time between coats.d 使用正確的噴漆壓力Use correct compressed air pressure.e 烘烤前適當(dāng)流平,避免加熱過快,熱源過近。Allow sufficient flash off time before force drying, ensur

5、e that the correct drying temperature is not exceeded. Do not allow the heat source to be placed too close to the surface.針孔(Pinholing描述(DESCRIPTION小凹穴,通常直徑小于1MM。Small cavities, generally less than 1 mm in diameter,預(yù)防(PREVENTION a一次不要噴得太厚。Do not spray too thick one time,b烘烤之前適當(dāng)流平。Flashing the film b

6、efore baking.c 使用涂料廠商推薦的附料。Use only recommended materials.d 正確調(diào)配油漆,使用較慢干稀釋劑。Mix the paint correctly, use slow dry thinner.E保持底材干凈。Keep materials clean.魚眼/ Fish Eyes (cissing產(chǎn)生魚眼的原因(cause:放大之后中間有核,通常是*素材被含硅silicon類的物質(zhì)污染。*素材未很好清潔。*裸手接觸工件。*油漆一次噴涂太濕。*油漆體質(zhì)敏感。預(yù)防(PREVENTION魚眼的產(chǎn)生Keep the part away from sili

7、cone pollutionThoroughly clean the surface with wax and grease remover. Do not allow cleaning solvents to dry on the surface but remove with a clean dry cloth,Always use the recommended materials.Ensure that the spraying area is properly ventilated.與魚眼相似的其它缺陷1.水泡(blister工件表面被濺上水珠。你見過水性漆出現(xiàn)此缺陷嗎?與魚眼相似的

8、其它缺陷2.油污(oil pollution工件表面被輕質(zhì)油污染.起云/斑紋,(Clouding / Mottling 起云/斑紋,(Clouding / Mottling 起因:常見于銀粉漆,主要是銀粉排列不一致。主要原因有:1十字交叉噴涂;2使用太差的稀釋劑;或稀釋劑加入太少。3槍未調(diào)好;4噴涂手法不正確。5素材厚薄不一(這種情況常叫應(yīng)力紋。臟點/纖維/異色點(Dirt / threads / Bits此類缺陷目前占有相當(dāng)大的比例,您知道其主要原因是什么嗎?顆粒(particles產(chǎn)生原因素材本身灰塵未被去除;油漆未過濾,或濾網(wǎng)太粗或太臟;噴房、流平間、烤房等環(huán)境被污染;調(diào)漆間臟污,油漆未

9、蓋好;調(diào)漆罐、供漆管路、噴槍清洗不夠。壓縮空氣未過濾,或濾網(wǎng)太臟。纖維或毛絲:主要來自衣服纖維,人員走動太多,未穿防塵衣。也有來自劣質(zhì)空氣過濾網(wǎng)。當(dāng)這類缺陷很多時,怎么辦?建議當(dāng)這類缺陷很多時,建議將缺陷樣品抽取30-50片進行詳細(xì)分類(有必要的話,使用放大鏡觀察缺陷形狀、顏色等,然后分析原因改善檢察改善效果制定SOP 貫徹執(zhí)行SOP。干噴/異常光澤低(Dry spray/loss of gloss描述(DESCRIPTION雖然漆膜表面光滑,但漆膜表面光澤異常偏低. Although apparently smooth and evenly applied, the surface lack

10、s shine.起因(CAUSEMicroscopic roughness of the surface which may result from:a底漆太差或底漆未干就噴面漆. poor hold out of primer, or the application of topcoat over primer which is not thoroughly dry.b稀釋劑太差或加了不合適的添加劑. poor quality or incorrect thinner, or the use of additives in the paint.c 素材前處理不當(dāng)或噴漆手法不對. incorr

11、ectly prepared or poorly applied paint.d 素材質(zhì)量太差application over a poor substrate.e 高濕低溫時漆膜干燥太慢. excessively slow drying due to high humidity or low temperature.f 溶劑蒸氣在漆膜表面冷凝. solvent fumes or exhaust gases attacking the surface.g 表面被污染. surface contamination by wax, grease, oil, soap or water.預(yù)防(PRE

12、VENTION a 選擇正確種類和比例的稀釋劑Use the correct proportion of recommended thinner.b 正確的噴漆手法: 槍距, 扇形, 氣壓Use correct spraying techniques, ensure that equipment is clean, set air pressure as low as possible, consistent with proper atomisation, spray from the correct distance.c 使用合適的噴房, 確保噴房有良好的空氣流通. Use a spray

13、 booth, and ensure that air circulation and extraction is at the correct velocity.漆膜太薄Inadequate Colour Coverage描述(DESCRIPTION漆膜過薄可見底材, 通常出現(xiàn)在比較難噴涂的底側(cè)面等地方. Underlying surfaces visible through the paint film, most frequently in hard to spray areas, on lower panels or on sharp edges and contours.預(yù)防(PRE

14、VENTIONa 使用合適的噴涂方法確保合適的漆膜厚度. Use the correct spraying technique, ensure even and adequate film thickness.b 使用合適的治具, 合適的燈光照明; 特別注意難噴涂表面. Work under good lighting conditions in a properly sized spray booth, pay special attention to inaccessible areas.c 確保漆料混合均勻. Ensure that the materials are thoroughl

15、y mixed.橘皮(Orange Peel 描述(DESCRIPTION 漆膜表面不平整如同桔子皮表面. Pebbled, uneven surface of the paint film, similar in appearance to orange skin.起因(CAUSEa噴漆手法太差, 槍距, 空氣壓力、出漆量調(diào)節(jié)不合適。b漆膜不要噴得太厚或太薄。cc 油漆品質(zhì)太差、粘度調(diào)整不合適、混合不均勻。d兩層漆之間干燥不夠。Insufficient drying time between coats.e 工件表面溫度不正常。Incorrect ambient or surface tem

16、perature, draughts.預(yù)防(PREVENTION a 使用正確的噴漆手法、正確調(diào)節(jié)噴槍。Use the correct spraying technique and ensure that equipment is correctly adjustedb均勻噴漆。c使用合適的天那水,并調(diào)節(jié)到合適的粘度。Ensure that the paint is correctly mixed, use only recommended thinner with the correct graded 兩層漆之間充分干燥。Allow sufficient drying time betwee

17、n coatse 在合適的溫度范圍內(nèi)和良好的空氣流通條件下噴漆。Spray within the re-commended temperature range and ensure proper ventilation流掛(Runs / Sags 流掛(Runs / Sags 描述(DESCRIPTION 通常在垂直面等處,出現(xiàn)漆膜局部過厚造成大波紋、乳頭現(xiàn)象。Well defined local thickening of the paint film in the form of a wavy line or shallow, rounded ridges, normally confin

18、ed to sharply sloping or vertical surfaces.起因(CAUSESlumping of the paint film due to:a 噴得過厚,空氣壓力太低,扇形太窄,槍距太近,運槍太慢。Excess thickness of application, air pressure too low, fan width too narrow, spray gun too close to the surface or moving too slowly.b 使用太差的天那水。Use of poor quality or incorrect thinner.c 粘度調(diào)整不正確。Incorrect viscosity of the paint.d 素材表面或氣溫太低。